Production method

ABSTRACT

A method for producing a panel including a core and a decorative surface layer is disclosed. The method includes the step of applying a dry powder layer on the core. The method includes the step of applying steam on a dry powder layer on the core. Thereafter heat and pressure are applied to the powder layer in order to bond the powder together.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 13/118,846, filed on May 31, 2011, which claims the benefit of U.S. Provisional Application No. 61/349,950, filed on May 31, 2010. The entire contents of each of U.S. application Ser. Nos. 13/118,846 and 61/349,950 are hereby incorporated by reference herein.

TECHNICAL FIELD

The disclosure generally relates to a method for producing a fibre-based building panel, preferably a floor panel, and to a building panel produced by said method.

BACKGROUND

A new type of panel called Wood Fiber Floor (WFF) is disclosed in WO2009/065769, which shows both products and methods to produce such a panel. Further methods and production equipments are disclosed in WO2009/124704.

The WFF floor panels are produce by applying a dry powder mix on a HDF core. The powder mix is bonded together under heat and pressure to form a decorative surface layer.

In order to stabilize the dry powder mix the production methods in WO2009/065769 or in WO2009/124704 (see page 15, line 15-21; FIG. 3) uses spraying of pure water or water with additives.

The entire contents of WO2009/065769 and WO2009/124704 are hereby incorporated by reference herein, and with a specific reference to page 15, line 15-21 and FIG. 3 of WO2009/124704.

SUMMARY OF THE DISCLOSURE

An objective of embodiments of the disclosure is to provide production methods that are more effective than the present known technology. Another objective is to produce panels with a more uniform colour or a more controlled colour variation and/or pattern.

When pressing a surface layer out of powder mix—such as a WFF mixture disclosed in WO2009/065769 or in WO2009/124704—one problem is to avoid that the powder mixture completely or partly blows off when the board is handled in the line before pressing and/or blow out of the press when the air is evacuated due to the closing of the press.

The known solutions to stabilize the powder by using spraying of water has the disadvantage that it is difficult to control the distribution of the water and to avoid water drops unintentionally falling down on the powder layer from the spraying unit.

An uneven water distribution and/or unintentional water drops normally have a negative effect of the visual as well as technical properties of the product. Furthermore, a waiting time to let the water penetrate into the powder before entering the press slow down the press cycle and to total out put from the production line is lowered.

A first aspect of the disclosure is a method of manufacturing a panel comprising a core (1) and a decorative surface layer (4) comprising the steps of:

-   -   Applying a dry powder layer (2) on a core (1); and     -   Applying steam to the powder layer.

The steam is preferably a water steam, most preferably a substantially pure water steam, even though the steam may comprise one or more additives. Examples of additives are wetting agents, releasing agents and/or colour additives.

The dry powder layer is preferably a mix of fibres, preferably wood fibres, and binder(s). The powder layer may also include wear resistant particles, preferably aluminium oxide.

The core is preferably a wood fibre based core, preferably an HDF panel.

A second aspect of the disclosure is a method of manufacturing a panel comprising a core (1) and a surface layer (4) with a designed pattern comprising the steps of:

-   -   Applying a dry powder layer (2) on a core (1); and     -   Creating a pattern by applying steam to parts of the powder         layer or applying steam unevenly (e.g., over all of the powder         layer, but in different amounts) over the powder layer.

The steam in the first and the second aspect is preferably a water steam, most preferably a substantially pure water steam, even though the steam may comprise one or more additives. The steam may be a mist or the gas phase of water (water vapour), preferably a saturated vapour and most preferably a saturated vapour mainly comprising water.

Preferred embodiments of the first and second aspects of the disclosure are disclosed below.

A third aspect of the disclosure is a panel produced according to any one the aspects above.

The methods above may be used to any production of a building panel in which a dry powder layer is applied to a core.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:

FIG. 1 Illustrates a production line and a method according to an embodiment of the disclosure;

FIGS. 2a-2b Illustrate a method for creating a design according to an embodiment of the disclosure;

FIG. 3 Illustrates a method for creating a design according to an embodiment of the disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

In FIG. 1 an embodiment of a production line is disclosed for producing a panel 5 with a decorative layer 4. A dry powder mix 2 is applied by scattering on a core 1, preferably an HDF core. The powder mix is stabilized by applying steam 3 before the powder mix is bonded together by applying heat and pressure in, for example, a press 9. If a pattern is desired, the steam may in one embodiment, be applied through a template 6, preferably rotating. In a preferred embodiment also a balancing layer 7 is applied to the core.

In the methods according to the present disclosure preferably the same scattering and pressing units as disclosed in WO2009/065769 or in WO2009/124704 are used.

In one embodiment the steam is applied by using a steam box 8, a box with one or more outlets at the bottom for steam, positioned above the transportation belt. The box preferably extends across the panel with a uniform width. An even moisture distribution is applied over the surface of the scattered powder layer 2, when the board pass under the steam box. Since the steam penetrate into the powder very effectively it is possible to immediately move the board into the press and close the press 9.

A suitable steam box is either fed by an external steam generator or the steam is generated in the steam box itself. It is suitable that that the steambox is equipped with one or several layers of nets for example mesh and/or sheets with holes to even out the steam concentration close to the powder layer.

FIGS. 2a and 2b shows how an uneven distribution of moisture 21, obtained by applying steam 3 through, e.g., a nozzle 25, can be used for design effect purpose. Different amount of moisture 21 in different parts of a single colour powder, but not yet pressed, surface gives a visual colour difference of the different parts. By controlling where on the surface the moisture content is higher a wanted design effect 22 can be generated (see FIG. 2b ) in the pressed surface 24 of the panel even if only one unicolored powder layer is applied on the core 1.

By controlling the relative movement between a core 1 with the powder mix layer 2 and one or several steam outlets a controlled variation of the content of moisture 21 in the powder can be achieved. This variation of moisture content will after pressing be visible as color differences 22 on the ready surface 24.

One or several of the steam outlets could be fixed on a robot arm and their position in relation to the scattered board could then be controlled in all directions.

The steam outlets 41 could be positioned in a rotating device, preferably a steam pipe 40, to generate a controlled moisture variation 42 in the powder layer 2, see FIG. 3.

As a Non-Limiting Example, the Steps for Producing a WFF Board could be as Follows:

-   -   1) Place a balancing layer, e.g. a paper impregnated with a         thermosetting resin or a mixture of wood powder and         thermosetting resin is placed on a transportation belt. A         typical balancing layer is two sheets of DKB 140 paper.     -   2) Place a wood fibre board, typically an about 10 mm thick HDF         board with a density of typically about 900 kg/m3, on top of the         balancing layer.     -   3) Moving the balancing layer and board in a speed of 1-10 m/min         (a typical value is about 3 m/min) under a scattering machine         were a premade mixture of wood fibres, binders, hard particles         and pigments are scattered on top of the board. The powder         applied can be in the range of about 100-1000 g/m2. Typical         value is about 700 g/m2.     -   4) Moving the board, with a balancing layer on the backside and         a scattered powder layer on the top side, through a steam box         with even steam concentration in the speed of 1-10 m/min         (typical value is about 3 m/min) where steamed water, with or         without additives, penetrates into the powder and stabilize it         to improve further handling and to avoid that the powder blows         out when the press is closing. Typical amount of moisture         applied by the steam box is 3 g/m2.     -   5) Bringing the board with a balancing layer on the backside and         a scattered and steam stabilized powder layer on the top side         into the press.     -   6) Closing the press, and curing the thermosetting resin in the         balancing layer and the powder layer under heat and pressure.         Typical press parameters are 30 seconds pressing (range is, for         example, 8-60 seconds). 40 bars pressure (range is, for example,         30-60 bars) may be applied on the board. Temperature of         typically about 170 degrees C. (range is, for example, 150-220         degrees C.) on the top and bottom press plates. The pressing         surfaces of the press plates can be even or have structure.         Structure depth typically about 0.5 mm (range for example about         0-1.5 mm).

In an alternative example also one or more paper sheets are applied after step 4.

An Example of a Production of a WFF Board with a Designed Pattern by Controlled Uneven Moisture Distribution:

-   -   1) Place a balancing layer, e.g. a paper impregnated with a         thermosetting resin or a mixture of wood powder and         thermosetting resin is placed on a transportation belt. A         typical balancing layer is two sheets of DKB 140 paper.     -   2) Place a wood fibre board, typically an about 10 mm thick HDF         board with a density of typically about 900 kg/m3, on top of the         balancing layer.     -   3) Moving the balancing layer and board in a speed of about 1-10         m/min (typical value is about 3 m/min) under a scattering         machine were a premade mixture of wood fibres, binders, hard         particles and pigments are scattered on top of the board. The         powder applied can be in the range of about 100-1000 g/m2.         Typical value is about 700 g/m2.     -   4) Moving the board, with a balancing layer on the backside and         a scattered powder layer on the top side, under one or several         steam outlets that also might move sideways and open and close         during the board passing time, in the speed of about 1-10 m/min         (typical value is about 3 m/min) where steamed water, with or         without additives, penetrates into the powder in an uneven but         controlled way to obtain a variation in the moisture content in         the powder layer.     -   5) Bringing the board with a balancing layer on the backside and         a scattered and steam stabilized powder layer on the top side         into the press.     -   6) Closing the press, and curing the thermosetting resin in the         balancing layer and the powder layer under heat and pressure.         The different moisture content resulting in a visible design         effect in the ready pressed board. Typical press parameters are         about 30 seconds pressing (range is, for example, about 8-60         seconds). About 40 bars pressure (range is, for example, 30-60         bars) may be applied on the board. Temperature of typically         about 170 degrees C. (range is, for example, about 150-220         degrees C.) on the top and bottom press plates. The pressing         surfaces of the press plates can be even or have structure.         Structure depth typically value about 0.5 mm (range for example         about 0-1.5 mm).

In an alternative example also one or more paper sheets are applied after step 4. 

The invention claimed is:
 1. A method comprising: applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder; subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer.
 2. The method as claimed in claim 1, wherein the steam is a saturated vapour consisting essentially of water.
 3. The method as claimed in claim 1, wherein the steam comprises one or more additives.
 4. The method as claimed in claim 1, wherein the core is a wood fibre based core.
 5. The method as claimed in claim 1, wherein the core is an HDF panel.
 6. The method as claimed in claim 1, wherein the formed panel is a building panel.
 7. The method as claimed in claim 1, wherein the formed panel is a floor panel.
 8. The method as claimed in claim 1, wherein the mix of the dry powder layer further comprises wear resistant particles.
 9. The method as claimed in claim 1, wherein the mix of the dry powder layer further comprises aluminium oxide.
 10. The method as claimed in claim 1, wherein the mix of the dry powder layer further comprises pigments.
 11. The method as claimed in claim 1, wherein the mix of the dry powder layer further comprises wear resistant particles and pigments, and wherein the binder is a thermosetting resin.
 12. The method as claimed in claim 1, wherein the binder is a thermosetting resin.
 13. The method as claimed in claim 1, wherein a thickness of the cured layer is less than about 1 mm.
 14. The method as claimed in claim 1, wherein a thickness of the cured layer is less than about 0.3 mm.
 15. The method as claimed in claim 1, wherein the cured layer is a surface layer of the panel.
 16. The method as claimed in claim 1, wherein the cured layer is a decorative surface layer of the panel.
 17. The method as claimed in claim 1, wherein the steam is applied with a steam box.
 18. The method as claimed in claim 1, wherein the dry powder layer is applied by scattering.
 19. The method as claimed in claim 1, wherein heat and pressure are applied by a press.
 20. The method as claimed in claim 1, wherein the press is operated with the following parameters: 8-60 seconds of pressing time; 30-60 bars of applied pressure; and 150-220° C. of pressing temperature.
 21. The method as claimed in claim 1, wherein the steam is applied to the dry powder layer when the core is moving at a speed of 1 to 10 meters per minute.
 22. The method as claimed in claim 1, wherein the steam is substantially uniformly applied over the dry powder layer.
 23. A method comprising: applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder; subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer, wherein the steam comprises one or more additives selected from the group consisting of wetting agents, releasing agents, and colour additives.
 24. A floor panel produced according to the method in claim
 1. 25. A floor panel produced according to the method in claim
 11. 26. A floor panel produced according to the method in claim
 22. 